EMCP 4.3/4.4 Panel Installation for 3512C and 3512C HD Land Drilling Applications{4490} Caterpillar

Engine:

3512C (S/N: LLK1-UP; LN51-UP; LD91-UP; LLA1-UP)

Introduction

This Special Instruction contains information for the installation of the "loose ship" panel for 3512C and 3512C HD land drilling application. The panel will house either an EMCP4.3 or an EMCP4.4. The information in this publication focuses on installing the new generator and engine components.

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Note: The EMCP panel does not come with a mounting bracket. A mounting bracket must be fabricated. Refer to the ECMP publication Application and Installation Guide, LEBE0007 for best mounting practices. Modifying the old mounting location brackets is not acceptable for mounting of the new panel.

Note: The following instructions will allow the EMCP to be configured properly if the following configuration is true. The engine must be configured for remote start and stop as described in the ""Remote Start" " section of this publication. If the configuration is not the same as described, refer to the Application and Installation Guide, LEBE0007 to ensure the proper configuration.

Use the latest version of Cat ET. The current version of Cat ET is "2014B".

Illustration 1	g03736689

Typical example of an installed unit

Illustration 2	g03737964
Typical example of a multi unit installation.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures may result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE".

Common Parts for All Applications

Table 2 provides information that is related to all applications.

Note: The part numbers listed in the following tables may not be the same part numbers that are used in your application. That is, the part numbers may be different due to the kV rating of the application.

Note: The control panel assembly is shipped without a stand.

Note: Terminate the wires at the AC Terminal strip in the generator terminal box. Match the circuit identification to the correct terminal block label. For example, the gray E486 wire must be connected to terminal E486.

Illustration 3	g03163320
EMCP 4 Control System Panel (1) Display screen (2) F4 Soft key (3) F3 Soft key (4) F2 Soft key (5) F1 Soft key (6) Control key (7) AC overview key (8) Engine overview key (9) Main menu (10) Warning Indicator lamp (yellow) (11) Acknowledge alarm key and silence key (12) Shutdown Indicator lamp (red) (13) Event reset key (14) Event log key (15) Run key (16) Auto key (17) Stop key (18) Escape key (19) Up key (20) Right key (21) OK key (22) Down key (23) Left key

Illustration 4	g03163216
Control panel (24) 275-2098 Oil Temperature Gauge Gp (25) 275-2100 Engine Percent Load Gauge Gp (26) 275-2096 Engine Oil Pressure Gauge Gp (27) 275-2081 Coolant Temperature Gauge Gp (28) 363-8626 Gauge (29) 275-2110 Voltmeter Gp (35) Gauges (36) EMCP 4 (37) Emergency stop (38) Generator AC inputs (39) Generator interface connector (40) Service port connector (41) Engine interface connector (42) Radio connector

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 for more information about the operation of the EMCP 4.4.

Note: The information in UENR1210 is related to a generator application, but not specifically to the application in this publication for dynamic gas blending.

Note: The following potential transformers and current transformer, shown in Illustration 5 are optional from Caterpillar or customer supplied.

Illustration 5	g03587224
(50) Potential transformer (51) Current Transformer As (52) Dot to indicate positive terminal (53) Dot to indicate CT polarity

The yellow dot (52) on the top of the current transformer is a reference to determine which post of the CT is positive or negative. The installer must confirm which post is positive or negative when the CT is correctly oriented. The yellow dot (53) on the side of the CT is used for polarity, the current flow direction, and orientation when installing the CT.

Shutting Down the Unit

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from any utility and/or other generators that can provide power service), and either lock out or tag as "DO NOT OPERATE". Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

1. Open the main circuit breaker in order to disengage the driven equipment.

2. Turn the engine control switch to the "OFF/RESET" position. The engine will immediately shut off.

3. Press the red "STOP" button on the controller. If the set point for the duration of the cool down period is set to a value that is greater than zero, the engine will operate for a programmed period before the engine stops. Otherwise, the engine will immediately shut off.

4. All power to the unit must be disconnected and locked out. All gas, fuel, hydraulic, and air must be blocked and/or locked out that is used for the unit. Some applications may require air or hydraulic accumulators to have the pressure relieved.

Remove Access Panels

Illustration 6	g03701070
Examples of other access panel installations

Illustration 7	g03163681
Typical example of access panel for customer connections. (54) Access hole for wiring harness (plug removed) (55) Large access cover (56) Smaller access covers

Note: There are multiple types of enclosures. Refer to Illustration 6 and 7 for two typical examples.

Remove access panel (55) to access the customer connections.

Note: Removal of the access covers (56) is not required for all applications.

Illustration 8	g03702009
Typical example of access covers removed.

Installation Procedure

Overview of Layout and Connections

Illustration 9	g03737619

Install Potential Transformers

Use the following steps to install the potential transformers.

Note: Due to the various types of enclosures or terminal boxes, the required location of components will vary. The illustrations in the following procedure show different mounting locations for the potential transformers.

Note: The installation of the potential transformers may be different if customer supplies the potential transformers.

1. Verify that the correct PT has been shipped. Check to make sure the part numbers of the PT are correct.

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Illustration 10	g03702163
PT location (60) Access hole (61) PT location

Note: The access hole (60) is used with the optional DC harness. The access hole (60) must be accomplished by the installer.

2. Examples for potential transformer location are shown in Illustrations 10 and 11. Place marks on the enclosure where the holes for the mounting bolts of the transformers are to be located.

3. Drill the mounting holes for the transformers.

4. Select the correct transformer wires that are to be used. Insulate the unused wires. Ensure that the correct mounting bolt and proper washers are used. Make sure that no wires from the PT are being pinched.

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Illustration 11	g03164044
Typical example of transformers installed (67) Potential transformer (68) Mounting bolt and washer (69) Transformer leads

5. Install the transformers (67). Ensure that the transformers leads are routed correctly so the leads will not be pinched during the install process. Refer to Illustration 11 and 12.

Illustration 12	g03737166

Note: The potential transformers can also be installed as shown in Illustration 12.

Install Current Transformers

Use the following steps to install the current transformers.

Note: The steps to install current transformers may be different than what is listed here if the customer provides the current transformers.

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Illustration 13	g03359941

1. Disconnect output cables (75) .

   Note: Ensure that the cables are appropriately labeled in order to ensure that the cables are installed correctly after the current transformer (CT) is installed.

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Illustration 14	g03587259
Typical example of a CT. (76) Dot to indicate positive terminal (77) Dot to indicate CT polarity

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Illustration 15	g03587261
Typical example of the CTs installed on output cables.

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Illustration 16	g03737181
Typical example of the CTs installed on output cables.

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Illustration 17	g03703300
Another example of a typical installation of customer connections

2. Install one CT on each group of output cables.

   Note: Ensure that the polarity dot (77) is facing the drive end of the generator.

3. Secure each CT with cable ties in the correct location. Cut off the excess length of the cable ties.

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Illustration 18	g03587263
Another example of a typical installation (78) Signal (sensing) lines (79) Dot to indicate CT polarity (80) CT connections

4. Connect the red signal (sensing) wires (78) .

   Note: Ensure the length for signal (sensing) wires and CT connections will long enough to reach the terminal strips.

5. Connect the wiring (80) for each CT. Refer to Illustration 18.

   Note: Remove any used CT. If the CT is not removed, the CT must be shorted.

6. Install all of the output cables on the correct bus bars.

Install Terminal Strip and 40 Pin Connector

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Illustration 19	g03164037
Another example of a typical installation (85) DIN rail installed

1. Install the DIN rail (85) in an appropriate location. The DIN rail (85) must be long enough to accommodate the terminal strip and PWM module.

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Illustration 20	g03739150
Typical installation example and hole dimensions. The dimensions are in millimeters. (86) Location for 40 pin connector (87) Installed connector

2. A hole (86) will need to be cut in the enclosure to allow installation the 40 pin connector (87) in an appropriate location.

   Note: Ensure that hole (86), is in a location that will not interfere with the terminal strip on the inside of the enclosure.

   Illustration 21 shows the location of the hole that is needed and the connector installed.

3. Prior to mounting the terminal strip, the area must be cleaned of any metal shavings and debris.

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Illustration 21	g03737620
Typical installation example (87) Installed 40 pin connector (88) Installed AC wire harness (89) Terminal strip (90) AC Terminal strip (91) CT leads

4. Mount terminal strips (89) and (90) .

5. Wire the CTs and PTs.

   Note: Refer to Special Instruction, REHS9148, "Wiring Diagrams" for wiring schematics information.

6. Feed the wire harness (88) through the enclosure and connect to the terminal strip (89) and (90) .

7. After wiring is completed, install all covers and access panels.

Install EMCP 4 Control Panel

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 for EMCP 4 concerns.

Note: The installation kit included the EMCP 4.4 control panel, however, the EMCP 4.4 was flashed with EMCP 4.3 software.

Refer to Application and Installation Guide, LEBE0007 for information related to the differences between the EMCP 4.3 and EMCP 4.4.

Install the EMCP 4 control panel in the appropriate location. The location of the panel is to be determined by the need of the customer. A stand for the control panel is NOT included.

Caterpillar does offer a stand for certain applications. However, for most applications, a stand will need to be fabricated.

The stand that is available by Caterpillar is 389-0244 Instrument Panel Mounting Gp .

Control Panel Stand

An example of a stand for the control panel is shown below. Refer to Special Instruction, REHS9148, "Panel Dimensions" section for control panel dimensions.

EMCP4 Control Installed

Illustration 22	g03176709

Caterpillar does offer a stand. However, the stand may not be appropriate for your installation. The part information for the stand that Caterpillar has available is listed in Table 4.

Harness Connector

1. Connect the wire harness connector to the connector (87) that was installed on the enclosure.

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Illustration 23	g03737651
Typical example of 40 pin and harness installation (87) Installed 40 pin connector (88) Installed AC harness (92) Rubber grommet installed to protect harness

Note: Ensure that the cable (88) has some type of protection, like a rubber grommet (92), where the cable enters the enclosure.

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Illustration 24	g03703376
Another typical example of installation (98) Access hole for connector assembly (99) Connector assembly installed

2. Route the wiring harness (88) to the EMCP panel.

   Note: Ensure that the harness wiring is the appropriate length to allow connections to the terminal strip.

3. Connect the wiring harness to the control panel.

   Note: Refer to Special Instruction, REHS9148, "Wiring Diagrams" for wiring schematics information.

Wiring Diagrams

Control Panel

Use the following steps to make necessary wiring changes.

Note: The following is the recommended configuration. If the current installation is different, refer to Application and Installation Guide, LEBE0007.

Note: The following example applies to a unit that uses the three position remote start/run, cool/stop, and stop switch. The three position switch is used in the earlier version of the control panel.

Illustration 25	g03737733
Schematic over view

Note: The potential transformer secondary is 240 V.

Note: The circuit that was used in one installation, shown in Illustration 25, no PMG was installed on the generator.

1. A wire 060-YL must be routed from the remote switch to the EMCP 4 control panel terminal strip. The 060-YL wire is connected to terminal 8 of the remote switch.

2. Connect wire 060-YL to the "START" terminal block on the terminal strip that is in the EMCP 4 control panel.

3. Connect 998-BR to the "BATT-" terminal block on the terminal strip that is in the EMCP 4 control panel. Wire 060-YL is connected to contact 5 of remote switch.

   Note: All other contacts and wires must be removed from the 40 pin connector.

When the remote switch is in "STOP" or "COOL/STOP" position, the EMCP will send the stop request signal to the engine controller. When the remote switch is in "START/RUN" position, the EMCP will send the start request signal to the engine controller.

Note: The engine will always go through a cool down cycle when using the remote start/stop.

Remote Start

The EMCP4 can accept a remote start signal. If the signal is activated, the EMCP will send an engine start request to the engine controller. If the remote start signal is removed, the EMCP will send a stop request signal to the engine controller. A momentary signal will not keep the engine running.

The remote start will become active when "START" is pulled to "BATT-". For more information, refer to the Application and Installation Guide, LEBE0007.

Illustration 26	g03172277
EMCP panel terminal strip

EMCP 4 Control Panel Connections

Illustration 27	g03171396
(105) E-stop, Start, and Batt- terminal block location (106) Blue jumper wire (107) CAN 1 terminator resistor (108) CAN 2 terminator resistor

E-Stop Connections

Perform the following steps to use a remote E-stop switch.

1. Remove the blue jumper wire (106). Refer to Illustration 27 and Illustration 28.

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Illustration 28	g03171736
Removal of jumper wire and installation of external E-stop switch wiring. (106) Blue jumper wire

2. Connect the E-stop leads to the E-stop terminal and the Batt- terminal. Refer to Illustration 28.

PT and CT Connections

Illustration 29 shows the location that potential transformers and current transformers must be connected, whether Caterpillar provided or customer provided.

Illustration 29	g03739559

Schematic is for reference only.

The application will determine the PTs and CTs that will be needed. That is, for example, if the generator output is wired for 240 V, the PT output will be 240 V. The black and white wire of the input must be used for the one to one ratio.

The following is another example. The output of the PT will be 240 V if the following configuration is used:

• The generator is wired for 600 V output

• The generator is wired to the black and red input wires of the PT

Note: The PT uses a 2.5 to one ratio for this configuration.

Refer to Illustration 30.

Illustration 30	g03171820
Schematic is for reference only. The voltage rating for the installation will determine which connections are correct. For example, installations that use 240 V will use the black and white wires. For installations that use 380 V, the black and green wires are to be used.

Illustration 31	g03320208

Direct Rack Connections - Without Accessory DC Harness

Note: There are two options for direct rack connections. One option is that the customer DOES NOT order a DC harness that is installed from the panel to the generator. The other option is the DOES order a DC harness that is installed from the panel to the generator.

If a DC harness is not ordered, then make the following connections. The connections are made directly to the EM-C4, 40 pin connector. The connector is located on the bottom of the EMCP control panel. The connector is the location for the 0-200ma signal from the governor output.

1. Install the DR+ wire to pin 11.

2. Install the DR- wire to pin 31.

Illustration 32	g03738707
(101) ECMP panel

Refer to Special Instruction, REHS0848, "3500 Direct Fuel Control Modification" for related information.

If the CDVR is used, the CAN 1 termination resistor must be removed if there is a CAN termination resistor at the CDVR. Refer to Illustration 27 for the location of the CAN 1 termination resistor inside the panel.

Direct Rack Connections - With Accessory DC Harness

If a DC accessory harness is ordered, make the following connections. The connections are made directly to terminal blocks that are located inside of the generator terminal box.

1. Connect the internal DC harness 361-7002 to the DC terminal strip 361-6974 as follows:

   1. Connect F702-YL to terminal PWM1+.

   2. Connect J842-GN to terminal PWM1-.

2. Connect the 0-200 mA actuator output of the governor to the terminal strip 361-6974 as follows:

   1. Connect the 0-200 mA+ to terminal PWM+.

   2. Connect the 0-200 mA- to terminal PWM-.

Programmable Discrete Input Connections

Illustration 33	g03172302
Programmable discrete inputs for the EMCP4.

The "BATT-" must be used as reference. Refer to Illustration 33 for the terminal blocks used for programmable discrete inputs.

For more information, refer to the Application and Installation Guide, LEBE0007.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 or Application and Installation Guide, LEBE0007 for the following information:

• Analog inputs

• Digital inputs

• Analog output

• Digital output

Low Idle Request

Refer to Illustration 33 for the terminal blocks used for the digital ground reference and the low idle request input.

The low idle request is initiated by completing the circuit between PW02- (the digital ground reference) and the low idle request terminal L972.

Normal operation is allowed when an open connection exists between PW02- (the digital ground reference) and the low idle request terminal L972.

Modbus Connections

Illustration 34	g03320722

Refer to Illustration 34 for connections related to the Modbus.

Refer to Systems Operation, Troubleshooting, Testing and Adjusting, UENR1210 and Application and Installation, LEBE0010 for EMCP 4 SCADA data link related information.

AC Harness Connector

Illustration 35	g03739980
457-6302 (3M) or 457-6300 (7M) Generator AC 14 pin connector

CDVR Equipped Installations

For installations that use the CDVR, refer to Specifications, Systems Operation, Testing and Adjusting, RENR7941.

For installations that use the IVR, refer to Special Instruction, REHS9106.

Startup and Operation

Startup and operation process.

For more information, refer to the Application and Installation Guide, LEBE0007 for the EMCP4.3 and EMCP4.4 control.

Panel Dimensions

Illustration 36	g03320228